TECH FOCUS AREAS: General Warfighting Requirements (GWR) TECHNOLOGY AREAS: Materials; Air Platform OBJECTIVE: Develop novel non-destructive evaluation (NDE) tools and algorithms that facilitate rapid assessment of thick scarf repairs and joints, including those that do not have a plate-like geometry. The NDE tools and/or algorithms should detect delaminations 6 mm in diameter and larger plus porosity equal to and greater than two percent in the vicinity of the scarf. The capability must detect these flaws if the scarf includes multiple layers of composite lamina and should be readily integrated into common non-destructive testing (NDT) inspection equipment. Algorithms to assist in data interpretation and analysis must be prepared to enable easy update and maintenance by organic Air Force resources. The algorithms should not be based on brute force artificial intelligence / machine learning but needs to include the human in the loop using the preferred Intelligence Augmentation approach defined by the Air Force. DESCRIPTION: Future concepts for composite aircraft include the use of bonded scarf joints either as part of the manufacture and assembly of the structure or repairs of manufacturing defects or damage experienced in service. These structures can be relatively thick when compared to current composite aerospace components, exceeding 50mm in total thickness. Typical NDT methods used for thinner composite structures include ultrasonic and thermographic-based techniques, where frequencies and diffusion fields are managed and analyzed by the trained inspector to provide the desired detection capability, nominally delaminations approximately 6 mm in diameter or porosity exceeding two percent of the local volume. However, these methods are challenged when considering the geometry of a thick scarf repair, especially if multiple layers of composite components are joined together at the location and the scarf penetrates the multiple layers. As the signal becomes quite complex, the signal analysis and interpretation capability can exceed the skill of a typical Level 2 nondestructive inspector. Thus, the Air Force is seeking novel NDE approaches and/or the development of algorithms that assist and augment the inspection via interpretation of the complex signals that result from the interrogation of these types of structures. It is important to note the Air Force is NOT interested in brute force Artificial Intelligence / Machine Learning approaches as they have been shown to not address the nuanced and outlier nature of the data of interest. The Air Force solution that has been successfully developed and implemented for metallic [ref] and composite [ref] structures use an approach called Intelligence Augmentation [ref] that combines the capabilities of statistical classifiers and other analytical algorithms with the human to optimize the decision-making process to detect features of interest emanating from defects. These algorithms eventually need to be integrated into commercially available NDT equipment to enable them to be supported by major equipment suppliers. In addition, the NDT tools and algorithms should be developed in such a manner to accommodate changes and/or updates detection criteria and/or types of data being analyzed to enable organic Air Force maintenance of the implemented solution in its final state. Another desired capability is to inspect or facilitate inspection of complex geometry configurations typically found on military aircraft where such scarf repairs will occur. This includes variability in the geometry, lay-up, and substructure to the region of interest. The tools and algorithms must enable the assessment of these highly variable geometric configurations. PHASE I: This topic is intended for technology proven ready to move directly into a Phase II. Therefore, a Phase I award is not required. The offeror is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase I-like effort, including a feasibility study. This includes determining, insofar as possible, the scientific and technical merit and feasibility of ideas appearing to have commercial potential. PHASE II: Eligibility for D2P2 is predicated on the offeror having performed a Phase I-like effort predominantly separate from the SBIR Programs. Under the Phase II effort, the offeror shall sufficiently develop the technical approach, product, or process in order to conduct a small number of advanced manufacturing and/or sustainment relevant demonstrations. Identification of manufacturing/production issues and or business model modifications required to further improve product or process relevance to improved sustainment costs, availability, or safety, should be documented. Air Force sustainment stakeholder engagement is paramount to successful validation of the technical approach. These Phase II awards are intended to provide a path to commercialization, not the final step for the proposed solution. PHASE III DUAL USE APPLICATIONS: The contractor will pursue commercialization of the various technologies developed in Phase II for transitioning expanded mission capability to a broad range of potential government and civilian users and alternate mission applications. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: Aldrin, J., C., Forsyth, D. S., and Welter, J. T., Design and Demonstration of Automated Data Analysis Algorithms for Ultrasonic Inspection of Complex Composite Panels with Bonds, 42nd Annual Review of Progress in QNDE, Incorporating the 6th European-American Workshop on Reliability of NDE, Vol. 1706, p. 120006, AIP Publishing, (2016) Aldrin, J. C., Lindgren, E. A., and Forsyth, D. S., Intelligence Augmentation in Nondestructive Evaluation, 45th Annual Review of Progress in QNDE, AIP, 2102, p. 020028, (2019). KEYWORDS: Composite aircraft; repair; manufacture; defects; damage; Structure; detection capability; delaminations; porosity; skill of a typical Level 2 nondestructive inspector; Non-destructive Evaluation; NDE; Artificial Intelligence / Machine Learning; tools and algorithms; highly variable geometric configurations.
